1. Maria Lupo Control Systems Engineer 1 CONTROL SYSTEM RETROFITS March 7, 2013

2. 2. Agenda Why perform a controls retrofit Levels of control BAS design considerations Retrofit process Case studies Q&A

3. 2. Why perform a controls retrofit? Occupant comfort and IEQ Improve operations and maintenance Graphical interface Features and capabilities Remote access Centralized alarm and monitoring Energy savings Unsupported equipment Redundancy requirements Flexibility and competition

4. 2. Data vs Information Who needs the information? –Internal system –Building engineer –Property manager Does the data allow easy analysis to show: –Trends –Inconsistencies Why perform a controls retrofit?

5. 2. Modern Features Ethernet transport Web-based (natively) Protocol agnostic Central alarm collection & distribution Central trend collection & analysis Global strategies & data sharing Multi-vendor & converged networks possible –But not always advisable….

6. 2. Levels of Control No controls Pneumatic controls Building Automation System –DDC (Direct Digital Controls) –PLC (Programmable Logic Controllers) –Standalone –Manual controls Hybrid

7. 2. Levels of Control- cont. Setpoint Sensor ErrorOutput Open Loop – no feedback mechanism Example – Pneumatic controls Change in output NOT incorporated.

8. 2. Levels of Control- cont. Setpoint Sensor ErrorOutput Closed Loop – feeds back result of the change Example – DDC damper position feedback Change in output IS incorporated.

9. 2. Levels of Control- cont. Setpoint Sensor ErrorOutput Sensor ErrorOutput Example – DDC daylight sensor and occupancy sensor integrated Cascaded Loop – multiple variables

10. 2. Levels of Control- cont. Zone Demand Setpoint Reset Output Sensor ErrorOutput Example – DDC optimize AHU static pressure / discharge temperature setpoint Adaptive Control – use algorithms Zone Demand

11. 2. BAS Design Considerations NC PC Network Switch NC Server UC XM TUC S UMC First Tier Second Tier Third Tier NC Network Controller PCProgrammable Controller UCUnitary Controller TUCTerminal Unit Controller UMCUnit Mounted Controller XMExpansion Module SSensor Operator Work Station

12. 2. Simple and prevalent in electrical and industrial systems Master/Slave- request -> response Master is a single point of failure Limited size No self documentation- rely on a register list Modbus Utilizes an Echelon chip to guarantee communication Standard network variable types Self documentation Dependent on the requirements and longevity of a single company. LonWorks Predominant industry standard protocol Scalable Self documentation Priority schemes to allow multiple writes Read/write of programs, schedules, etc. Not all BACnet controllers are created equal BACnet BAS Design Considerations- cont.

13. 2. Joint Operations Center BAS Design Considerations- cont.

14. 2. Subsystem Characteristics Specialty components Best fit for each - best of breed or best value Range of sophistication / complexity Various O&M interfaces, service tools Degrees of openness / interoperability / standards

15. 2. BAS Design Considerations- cont. LIGHTING CONTROL ELECTRICAL MONITORING BAS IRRIGATION GAS DETECTION FUEL OIL SECURITY AUDIO/ VISUAL LIFE SAFETY System Integrations

16. 2. Integrations don’t resolve subsystem inefficiencies Potential benefits: –Implement “global” strategies Use lighting occupancy sensor to drive HVAC zone modes Schedule in one place Analyze trended data in one place Peak reduction / load shed (manual only, automatic peak reduction, utility-driven load shed) –Reduced O&M training –Better O&M results Required first step to deploying Advanced BAS software tools BAS Design Considerations- cont.

17. 2. INVESTMENT DESIGN/CONSTRUCTION ACTIVE MANAGEMENT INVESTMENT RELEASED PERFORMANCE ENHANCEMENTS BUILD USE REPAIR/ SERVICE The Facility Lifecycle

18. 2. Retrofit Process Evaluate facility and existing systems Create strategies and tactics for upgrade Define and design Implement then commission Key Factors for Success –Realistic expectations –Clear and defined specification –Attaining capable local controls representation –Performance verification Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

19. 2. Age and existing conditions Building construction limitations? Document existing system in detail What options are there for controls replacement? –Manufacturers –Product lines –Providers / installers –What technologies apply? Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

20. 2. AI "C2-1WEST", "152-T", "119&121 P-S Office Temp" HARDWARE "NC2-HW", "152" GRAPHICS 0, 0 N2OPENHW "AI", 1 UNITS "DEG F", 1 ALARMSET 1.000000,,, 58.00000, 80.00000, 0 REPORT N, Y, N, N,,, 6, 0, 0, 0 BO "NC2-SW", "115-C", "FAN-C" HARDWARE "NC2-HW", "115" GRAPHICS 0, 0 N2OPENHW "BO", 1, N UNITS "OFF", "ON", Y, Y, Y RESET Y TIMER 5, 1, 0, 255 REPORT N, Y, N, N,, 0, 0, 0 pt typesystem namept namept descriptionunitsio address controller AIC2-1WEST152-T119&121 P-S Office Temp Deg F 1152 BONC2-SW115-CFAN-C OFF, ON 1115 Raw Data Organized System Information Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

21. 2. What are requirements? What are dependencies? What is easy/difficult? Phased approach? How mature are the potential retrofit options? How integrated? Is a beta test or proof of concept warranted? Do upgrades affect other disciplines? (e.g. IT) Define the team needed Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

22. 2. Budget estimating Look at all affected systems –BAS (hardware and software) –Cabling / pathways –Power –IT systems Understand costs/savings of phasing Don’t forget to define “soft” costs and savings How does project phasing change based on the upgrade paths/options? Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

23. 2. Full design or design/build? Enhance core MEP systems? Replace entire system or selected upgrades? Address all affected systems –Controls –Cabling/pathways –Data network Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

24. 2. Decide on qualified vendors Use general contractor? Multiple subs? Understand phasing approach and build into the documentation Define warranties, maintenance, and support Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

25. 2. First tier network –Can Ethernet infrastructure be re-used? –Standalone network or part of Owner’s IT infrastructure? –Who will manage and maintain the system? –Requirements for operator workstations –System redundancy Servers Power –What is the electrical distribution? –Define where multiple protocols need to be supported –Strategically locate controllers on plan –Avoid >60 second tier controllers per network controller Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

26. 2. Second tier network –Controller electronics ~15-20yrs –New first tier products introduced <10yrs –New second tier products introduced ~10-12yrs –Are terminal units near end of life? –Separate second tier networks based on communication speed –Is spare capacity required on controllers? Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

27. 2. Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration Understand current system operation Optimize sequences of operation

28. 2. Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration Minimum and maximum outdoor air damper sections Additional sheet metal Low leakage dampers Blade seals Durable

29. 2. Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration Wiring trough Consider metering major systems –Meter locations Avoid control of equipment over the network. All points associated to a system should reside on the same controller.

30. 2. Procurement Methods – Single Vendor Security Lighting Controls BAS Life Safety Electrical A/V Dashboard Tenant Interface Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

31. 2. Procurement Methods – Fully Integrated Security Lighting Controls BAS Life Safety Electrica l A/V Dashboard Tenant Interface Div.26 Div.23 Div.28 Div.26 Div.28/Owner Div.27/Owner Div.25? Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

32. 2. BAS Centric Security Lighting Controls Life Safety Electrical A/V Dashboard Tenant Interface Div.26 Div.28 Div.26 Div.28/Owner Div.27/Owner Div.23 BAS Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

33. 2. Interview various contractors Compare capabilities Training and support Similar project experience with the same product line Contractor Evaluation Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

34. 2. Start with upgrades to infrastructure Install new, fully programmed devices before tearing out old devices – timing is everything! Have all points lists and database programming done in the shop before ever coming onsite Utilize independent commissioning agent as well as contractor self-commissioning Controls Assessment Defined Strategies BAS Design & Procurement Implementation & Construction Administration

35. 2. Case Study A – Multi-Building Campus Project Overview Existing Multi building campus; > 1 million sqft Predominantly office space New owner, owner occupied Hybrid of pneumatic and legacy DDC controls Compressed construction schedule

36. 2. Case Study A – Multi-Building Campus Vision Single building automation system Reuse of existing controls where possible Retrofit of all pneumatic controls Open business controls architecture System Integrator Controls Contractors BACnet, Modbus One Technology Platform Open Licensed Software Competitive Vendor Pricing One Graphical User Interface Reduced O&M

37. 2. Case Study B – Single Building Project Overview 17 story building Predominantly office space Existing owner, leased tenant space Hybrid of pneumatic and legacy DDC controls Single Vendor Support Upgrade from Proprietary to BACnet Protocol O&M of a Single System BACnet Proprietary

38. 2. In Summary Why perform a controls retrofit Levels of control BAS design considerations Retrofit process Case studies

39. 2.